Preparation of Iodixanol

ABSTRACT

A process for the preparation of iodixanol by dimerisation of 5-acetamido-N,N′-bis(2,3-dihydroxypropy1)-2,4,6-triiodo-isophthalamide (“Compound A”) in which, after the dimerisation step, unreacted Compound A is precipitated from the reaction mixture and recovered for re-use. The process substantially increases the net yield of iodixanol and simplifies its purification.

This application is a continuation of U.S. application Ser. No.12/245,886 filed Oct. 6, 2008 which is a continuation of U.S.application Ser. No. 11/958,714 filed Dec. 18, 2007, abandoned, which isa continuation of U.S. application Ser. No. 11/680,716 filed Mar. 1,2007, abandoned, which is a continuation of U.S. application Ser. No.11/288,029 filed Nov. 28, 2005, abandoned, which is a continuation ofU.S. application Ser. No. 09/923,074 filed Aug. 6, 2001, now U.S. Pat.No. 6,974,882 granted Dec. 13, 2005, which is a continuation ofInternational Application number PCT/GB00/00413, having an internationalfiling date of Feb. 10, 2000 which claims priority to Great Britainapplication number 9903109.8 filed Feb. 11, 1999 and claims benefit ofU.S. application Ser. No. 60/121,539 filed Feb. 25, 1999.

This invention is concerned with the synthesis of iodixanol.

Iodixanol(1,3-bis(acetamido)-N,N′-bis[3,5-bis(2,3-dihydroxypropylaminocarbonyl)-2,4,6-triiodophenyl]-2-hydroxypropane)is a non-ionic X-ray contrast agent which is currently manufactured inlarge quantities. A number of methods are known for its preparation butthese are all multistep processes and the cost of the final formulatedproduct thus mainly depends on these processes. It is thereforeimportant to optimise these processes for both economic andenvironmental reasons.

Three main processes are known for the preparation of iodixanol, all ofwhich start with 5-nitroisophthalic acid. In the first process (NO161358), the following route is used, via the final intermediate5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-isophthalamide(“Compound A”):

The problem with this process is that a yield of only 18% is reported inthe given example, and the product is purified by preparativechromatography. When we have repeated the example, we have found thatthe low yield is due to incomplete conversion (dimerisation) of CompoundA to iodixanol. After 40-60% of the starting material is consumed,over-alkylation of iodixanol starts to dominate over the desiredreaction, causing the net content of iodixanol in the reaction mixtureto decrease. In fact, 40-60% conversion to iodixanol seems to be themaximum obtainable. Due to this low conversion, common crystallisationtechniques are not able to purify the product to the necessary level,and preparative liquid chromatography is the only way to obtain a pureproduct. The combination of low yields with an expensive purificationmethod such as preparative chromatography is a serious disadvantage inan industrial process.

Priebe et.al. (Acta Radiol. 36 (1995), Suppl. 399, 21-31) describeanother route which avoids the difficult last step of the above process.However, the route involves eight reaction steps from 5-nitroisophthalicacid, which is undesirable, and one of the steps includes chlorinationwith thionyl chloride, which is extremely corrosive. Also, theintroduction of the iodine atoms takes place very early in the sequence,which is disadvantageous as iodine is the most expensive reagent in theprocess. The yield and final purification method for this route have notbeen reported.

The third route to iodixanol involves the synthesis of5-amino-2,4,6-triiodoisophthalic acid (WO 96/37458) and then itsdichloride (WO 96/37459), followed by conversion into Compound A (U.S.Pat. No. 5,705,692) and finally dimerisation as in the first processabove. This method thus has the same disadvantages as the first, andalso uses an undesirable acid chlorination step.

We have now surprisingly found that unreacted Compound A from onedimerisation batch, as produced for example in the first and thirdprocesses described above, can be recovered from the reaction mixture bya very simple process, and reused in a later batch. This increases thenet yield from successive batches on an industrial scale dramatically.Additionally, the removal of most of the unreacted Compound A from thereaction mixture allows the expensive preparative liquid chromatographypurification to be replaced by conventional crystallisation methods,still providing iodixanol suitable for pharmaceutical use.

The invention thus provides a process for the preparation of iodixanolby dimerisation of Compound A in which, after the dimerisation step,unreacted Compound A is precipitated from the reaction mixture andrecovered for re-use.

The dimerisation step itself may be carried out as described in NO161368 and WO 98/23296, for example using epichlorohydrin,1,3-dichloro-2-hydroxypropane or 1,3-dibromo-2-hydroxypropane as thedimerisation agent. The reaction is usually carried out in a non-aqueoussolvent such as a C₁₋₆ alcohol, preferably 2-methoxyethanol or methanol,and generally results in the conversion of 40-60% of Compound A toiodixanol. Dimerisation in pure water or mixtures of water and one ormore alcohols (e.g. C₁₋₆-alkanols) is also possible.

Precipitation of Compound A from a non-aqueous reaction mixture can beeffected after addition of water, for example in an amount of 1-2,preferably 1.3-1.8 L/kg Compound A used as starting material. If wateris present in the reaction mixture, the amount of water added forprecipitation can be reduced accordingly. An alcoholic co-solvent (e.g.a C₁₋₆ alkanol such as methanol) may additionally be used, for examplein an amount of 0.5-2, preferably 0.8-1.5 L/kg Compound A used asstarting material. In some instances, traces of undissolved materialremain after the addition of water and alcohol and these can bedissolved by addition of alkali, e.g. sodium hydroxide. The pH of thesolution is then adjusted to about 10-11 by addition of an acid, e.g.hydrochloric acid, to provoke precipitation of unreacted Compound A andif necessary the temperature can be adjusted to 15-40 C, preferably18-30 C. The solution is optionally seeded with crystals of Compound Ato initiate the precipitation of Compound A, while the iodixanol formedstays in solution.

Further addition of acid to a pH of 2-5, preferably 3-4, can increasethe yield of the recovery process by increasing the supersaturation ofnon-ionic Compound A. After this final pH adjustment, the suspension isadvantageously stirred for some hours to enhance the precipitation ofCompound A, e.g. 4-30 hours, preferably 8-20 hours. The precipitateshould then be separated from the reaction mixture by a conventionaltechnique, such as centrifugation or filtration, and optionally washedwith a suitable solvent, e.g. water or methanol.

The filtrate from the separation mainly contains iodixanol and smallfractions of related iodinated aromatic compounds, in addition to saltsand remaining epichlorohydrin and derivatives thereof. This mixture canbe purified by conventional desalination and crystallisation methods toobtain iodixanol suitable for pharmaceutical use. Chromatographicpurification of the crude iodixanol in the filtrate is not necessary.

The separated Compound A from the recovery process can optionally berecrystallised, for example from water/methanol or another alkanol.Thus, the moist material from the filtration/centrifugation may bedissolved in water in the presence of alkali. The amount of water shouldbe about 2-7 l/kg of Compound A, preferably 3-5 l/kg. Alkali, e.g.aqueous sodium hydroxide, should be added until all traces ofundissolved material are removed. The solution may optionally befiltered to remove remaining traces of undissolved matter. An alcohol,e.g. methanol (0.5-1.5 l/kg of Compound A, preferably 0.5-1.0 litres/kg)may then be added, and the mixture heated to 40-80° C., preferably50-60° C. Adjustment of pH by an acid, e.g. hydrochloric acid, causespure Compound A to precipitate. The mixture may optionally be seededwith a small amount of Compound A crystals. Maximum yield from therecrystallisation is obtained if the pH is finally adjusted to about5-7, e.g. with hydrochloric acid, followed by cooling to 10-25° C. Theslurry may optionally be stirred at this temperature to enhance thecrystallisation, e.g. 2-18 hours. The precipitate is separated from thesuspension by any conventional technique, for instance centrifugation orfiltration, and optionally washed with water, methanol or anothersuitable alkanol. The recovered Compound A may advantageously be dried,e.g. under reduced pressure, before reuse in a new dimerisation.Recovered Compound A, together if necessary with further fresh CompoundA, may be used in a new dimerisation reaction as described above,followed by subsequent recovery of unreacted Compound A. The inventionthus also includes process in which iodixanol is prepared in a series ofsuccessive processes according to the invention in which, after thedimerisation, unreacted Compound A is precipitated from the reactionmixture and recovered, optionally crystallised, and then re-used in asubsequent process in the series. The dimerisation reactions in such aseries will normally be substantially identical, and the unreactedCompound A will normally be recovered after each dimerisation step.

The following examples illustrate the invention.

EXAMPLE 1

Compound A (366 g) was dissolved in a solution of NaOH (23 g) in2-methoxyethanol (360 ml) at 50° C. The temperature was decreased to 15°C. when all solids were dissolved, and conc. HCl (28 g) was added to thesolution. Epichlorohydrin (13 g) was added in one portion, and thereaction was monitored by HPLC. After 46 hours the content of iodixanolin the reaction mixture was 49.6%. Water (575 ml) was added, and thetemperature was increased to 19° C. The solution was at this time clear,so no further addition of sodium hydroxide was necessary. The pH wasadjusted to 10.8 by 18% hydrochloric acid, and the solution seeded with1 g of Compound A. The pH of the resulting suspension was furtherpH-adjusted with 18% hydrochloric acid to pH 4.0. The suspension wasleft with stifling overnight before filtration and washing with water(60 ml) on the filter. The filtrate was further desalinated andcrystallised by conventional methods, providing iodixanol suitable forpharmaceutical use. The material on the filter was analysed on HPLC,showing 94.3% Compound A and 5.1% iodixanol.

EXAMPLE 2

The recovered Compound A from Example 1 was taken directly from thefilter without drying, and completely dissolved in water (440 ml) and50% aqueous NaOH (15 ml). The solution was filtered through a 3 μmfilter to remove traces of insoluble matter, and some more water (50 ml)was added to the filtrate. Methanol (95 ml) was added to the solution,and the temperature was increased to 60° C. The pH was reduced from 11.5to 9.8 with 18% hydrochloric acid, and 0.8 g seeds of Compound A wasadded. After 30 minutes, the pH was further reduced to 6 with 18%hydrochloric acid. The temperature was gradually reduced to 15° C., andthe precipitated material was filtered, washed with methanol (140 ml)and dried under vacuum at 60° C. The yield of pure Compound A (>99% byHPLC) was 118 g, corresponding to 32% of the starting material inExample 1.

The recovered Compound A (118 g) was combined with fresh Compound A (248g) in a new dimerisation similar to Example 1, giving nearly identicalresults as in Example 1.

1. A process in which iodixanol is prepared in a series of successiveprocesses by dimerisation of5-acetamido-N,N′-bis(2,3-dihydroxypropyl)-2,4,6-triiodo-isophthalamide(“Compound A”) in which, after the dimerisation step, unreacted CompoundA is precipitated from the reaction mixture and recovered, optionallycrystallised, and then re-used in a subsequent process in the series. 2.A process according to claim 1 in which the dimerisation step is carriedout using epichlorohydrin, 1,3-dichloro-2-hydroxypropane or1,3-dibromo-2-hydroxypropane as the dimerisation agent in a non-aqueoussolvent or in water or a mixture of water and one or more alcohols.
 3. Aprocess according to claim 2 in which the dimerisation agent isepichlorohydrin and the solvent is 2-methoxyethanol or methanol.
 4. Aprocess according to claim 1 in which precipitation of Compound A iseffected with water, optionally together with an alcoholic co-solvent.5. A process according to claim 4 in which the pH of the mixture isadjusted to 10-11 with acid to provoke precipitation, the temperatureadjusted if necessary to 15-40 C and the solution optionally seeded withcrystals of Compound A.
 6. A process according to claim 5 in whichfurther acid is added to a pH of 2-5.
 7. A process according to claim 1in which the Compound A recovered is recrystallised.
 8. A processaccording to claim 1 in which, after separation of Compound A, theiodixanol-containing mixture is purified without the use ofchromatographic methods.
 9. A process according to claim 1 in which therecovered Compound A is re-used in a subsequent process for thepreparation of iodixanol.